International Journal of Engineering and Advanced Technology (IJEAT) ISSN: 2249 – 8958, Volume-9 Issue-1, October 2019

Utilization of Participatory Ergonomics for Workstation Evaluation Towards Productive Manufacturing

Anna Liza C. Nacion, Alma L. Tangcuangco

the wellness of the individuals utilizing it. Workers Abstract: Principles of workstation configuration decrease profoundly presented to physical factors at the work work environment ergonomic and improve worker’s environment are bound to report manifestations of MSDs [1]. productivity. The participatory ergonomics approach is one of the According to Burgess-Limerick [4], participatory ergonomics best methods for eliminating or upgrading manual tasks with the improves efficiency and decreases hazard to and aim of reducing the occurrence of related occupational musculoskeletal issue. This study assesses the workstation of a wellbeing of an individual. foundry shop in terms of musculoskeletal occurrences and As stated by Middlesworth [5] there are five proven ergonomic hazards employing Ergonomic Symptom Survey, benefits of a strong workplace ergonomics process, these are: Illumination Measurement, Noise Measurement, and Postural ergonomics reduces costs; improves productivity; improves Analysis using REBA and RULA. The molding area average lux quality; improves employee engagement; and creates a better reading of 97.12 was far below the recommended light levels set by . By planning a workstation to take into the DOE. The production area produces unbearable noises. consideration great stance, less exertion, less movements and REBA and RULA results reveal that activities in the foundry shop better statures and scopes, the workstation turns out to be are very risky and need immediate investigation and changes. In general, the workstation is not properly layout. Improvement of more effective. Moreover, if workers do not experience material handling equipment such as the use of trolleys, rolling weariness and distress during working hours, it can diminish shelves or belt conveyors lessen the transfer time from one process absenteeism, improve confidence and increase worker to another leading to reduction of the current production time. In involvement. most cases, maintaining and safety practices provides a The rationale of this study is to evaluate the ergonomics much better way for the production performance of the foundry risk factors present in the foundry shop associated with MSDs shop as well as its workers. using Participatory Ergonomics approach.

Keywords: Musculoskeletal Disorder, Workstation Evaluation, II. METHODOLOGY Participatory Ergonomics, REBA, RULA The following methods were employed in evaluating the I. INTRODUCTION workstation of the foundry shop. A. Ergonomic Symptom Survey Ergonomic issues at the workplace and horrendous In identifying parts of the workers’ bodies that are affiliation are a bit of the contributing risk factors to word experiencing increased level of discomfort resulting from related security and restorative issues. Different conditions poor job design, the Musculoskeletal Discomfort (MSD) form inside the workplace are speculated to add to the extending based on the Nordic Questionnaire [6] was employed. enormity of musculoskeletal disorders (MSDs) suffered by Moreover, this symptoms survey helps to find out when the workers, including postural stress from postponed sitting, workers are experiencing not only discomfort but also pain, or standing, or ungraceful position; stereotyped and bleak developed disability that may be related to workplace endeavors inciting unending harm; peak over-load wounds to activities. the vital or periphery skeleton; biological parts; and mental B. Illumination Measurement factors including mental nerves, work dissatisfaction, and One of the fundamental ergonomic principles is to complex social issues [1]. provide adequate lighting. Poor lighting is a common Ergonomics is frequently seen in a disentangled manner problem in the workplace that can affect worker’s comfort as it focuses mainly on the physical aspects of work; force, level and performance. To assess the lighting, a light meter, repetition rate and posture [2]. According to Dohrmann infrared distance meter and lighting survey form were used. Consulting [3], ergonomics is the process of planning or The illuminance reading was evaluated using the guideline of arranging work environments, products and frameworks for Department of Energy (DOE) [7].

Revised Manuscript Received October 05, 2019 Formula: Lighting Index = Anna Liza C. Nacion, Alma L. Tangcuangco,

C. Noise Measurement Nowadays, occupational noise exposure is one of the most prevalent health concerns found in the workplace. Noise

Retrieval Number: A9702109119/2019©BEIESP Published By: DOI: 10.35940/ijeat.A9702.109119 Blue Eyes Intelligence Engineering 579 & Sciences Publication

Utilization of Participatory Ergonomics for Workstation Evaluation Towards Productive Manufacturing

induced is a common injury occurring in foundry Table 2. Distribution of Reported MSD work [8]. A sound level meter was used in finding the specific source of noise in a workplace. OSHA has a regulatory standard which has a criterion and threshold of 80 dBA – 90 dBA. D. Postural analysis Postural analyses tools used to evaluate work posture are Rapid Upper Limb Assessment (RULA) [9] and Rapid Entire Body Assessment (REBA). Ansari and Sheikh [10] conducted evaluation of work posture using RULA and REBA. Awkward postures used in the workplace may lead to work Based on the discomfort survey results, almost all the pain and injury [11]. The evaluation of the body posture was production workers claimed injuries in their body parts during carried out using the REBA tool. The REBA is a postural their stay in the company. These results are indications that analysis tool sensitive to musculoskeletal risks in a variety of the workers have a great risk of having MSD. tasks and assessment of working postures [12]. RULA, on the other hand, is a survey method developed for use in ILLUMINATION ergonomics investigations of workplaces where work-related The shearing and molding areas are too dim (Figure 4). upper limb disorders are reported [13]. Below represents the The lighting indexes in the shearing and molding area are level of MSD Risk based from the generated score. 3.22W/m2 and 2.38W/m2, respectively. These data are below For REBA Results the maximum lighting power density. The minimum lux Score Level of MSD Risk Recommended Action reading of 35 lux (corner) and the maximum lux reading was 1 Negligible risk No action required 348 lux (open area), on the average the measured lux was 2 – 3 Low risk Change may be needed 97.12 lux which is far below the recommended light levels set 4 – 7 Medium risk Further investigation, change soon by the DOE. As to the recommended design, illuminance 8 – 10 High risk Investigate and implement level of lighting for working interiors in general offices is 300 change – 750 lux (lumen/m2). Above 10 Very high risk Implement change Dimly lit workplace causes eye fatigue and put workers at a greater risk of getting injuries. The other source of light in For RULA Results Score Level of MSD Recommended Action this area that comes from the polycarbonate sheets mounted in Risk the roof is from the overhead holes in the wall of the 1 – 2 Negligible risk No action required production area that serves as windows. However, these holes 3 – 4 Low risk Change may be needed produce glare that causes headaches and also affects the 5 – 6 Medium risk Further investigation (change eyesight of the workers. soon)

Above 6 Very high risk Implement change now Noise and Vibration E. Workstation analysis Table 3 shows the testing result of the sound level in the Mali and Vyavahare [14] found out that ergonomic foundry shop. The results show that the shearing area (Ave. problem are major issues faced by the foundry industry, and 112.73 dBA) is the main source of noise in the area followed that the workstation layout and work design were found to be by the kiln area (105.75 dBA).

affecting workers’ efficiency most. Table 3. Sound Level Testing

III. RESULTS AND DISCUSSION Employee Job Average Sound Pressure level (dBA) A preliminary survey was carried on visits to and Employee 1 Kiln Operator 107.3 observation of a foundry shop workplaces during which Employee 2 Kiln Operator 104.2 problems relating to the working conditions of the workers Employee 5 Molder 74.3 were noticed. Employee 7 Molder 72.5 Employee 9 Molder 75.7 Table 1. Profile of the Workers Employee 10 Lathe Man 113.2 Gender All are male Employee 12 Lathe Man 110.4 Ave. Height (cm) 166.10 Employee 13 Lathe Man 114.6 Ave. Weight (lb) 133.76 Employee 16 Finisher 98.4 Employee 21 Finisher 86.7 Twenty-one (21) out of the total 40 production workers

were the respondents of the study. Table 1 and table 2 present the results of the survey. All the workers in the production area are male with an average height and weight of 166.10 cm and 133.76 lbs, respectively. The most claimed injury among the workers is the both wrist (80.96%), followed by both shoulders (71.43%). It should be noted also that all the molders experienced low back pain while all the kiln operators experienced upper back pain. Furthermore, four (4) of the workers claimed injuries in the knee.

Published By: Retrieval Number: A9702109119/2019©BEIESP Blue Eyes Intelligence Engineering DOI: 10.35940/ijeat.A9702.109119 580 & Sciences Publication International Journal of Engineering and Advanced Technology (IJEAT) ISSN: 2249 – 8958, Volume-9 Issue-1, October 2019

Figure 3 Worker’s Posture in the Molding Area

Figure 1 Sample Noise Testing The shearing worker also exhibits an awkward posture of holding fixed grip during the process. Moreover, the worker The noise inside the production area is unavoidable and exerts more force in performing this job (Fig. 4). also unbearable; this is due to the improper feeding of metals that are being transferred to the kiln and when the workers shear the molded pots. Moreover, the shearing process produces a very loud clatter that the office workers hear it even they are inside their working area.

Figure 4 Worker’s posture in the Shearing Area

The drilling worker also exhibits an awkward posture and at the same time the pot that is being drilled is being pressed to his knee during the process resulting to pressure points or local contact stress (Fig. 5).

Figure 2 Shearing Area affected by Noise and Vibration

Foundry workers are exposed to forceful exertions and vibration [15]. The shearing operator is exposed to hand-arm vibration. The lathe machine is used in the shearing process which rotates the metal pots and covers during which the operator trims the inside bottom and edges with the shearing blade. The hearing acuity of the worker might be threatened [16] because during this process the shearing operator is not wearing earplugs or any hearing protection. Posture During the preliminary information-gathering, awkward postures of workers were observed, as seen in Fig. 3. The Figure 5 Worker’s Posture in the Drilling Area activities performed by the manual molding workers require Based from the results of the REBA assessment of the physical exertion especially when handling molds when they workers in Fig. 3 and Fig. 5 the REBA Scores were 14 and 13, are being fashioned. In performing this repetitive activity, respectively, an indication that these were very high-risk workers stand/sit in an awkward posture, which is a causal positions. The RULA assessment of the worker in Fig. 4 is 7 factor for fatigue [11] and higher rate of lower back pain. with also a very high level of MSD risk. This corroborates the result of the MSD survey that all the Thus, the REBA and RULA employee assessment results workers assigned in the molding area had trouble in their reveal that the activities of the foundry workers are very risky lower back during the last 12 months. and need immediate investigation and changes.

Workstation The working environment of foundry is generally hazardous which leads to injuries of foundry workers [16] [17]. In the current layout of the Foundry Shop, backtracking is very visible. The aisle used in moving the scrap aluminum to the kiln is very narrow. When the kiln operator transfers the raw materials to the kiln using a wheel borrow, the aisle cannot be used by the other workers considering that this is the only way that connects the

Retrieval Number: A9702109119/2019©BEIESP Published By: DOI: 10.35940/ijeat.A9702.109119 Blue Eyes Intelligence Engineering 581 & Sciences Publication

Utilization of Participatory Ergonomics for Workstation Evaluation Towards Productive Manufacturing molding area with the shearing area. The molding area is divided into two areas; one for the pots and the other is for the pot covers. The molders have a hard time carrying the melted aluminum because they need to pass through the corners of the kiln that separates it to the molding area (Fig. 6). The storage area of the molded products is very far (approx. 45 meters) from the next process, this requires more time for the workers to transfer them in the shearing area. It is also worth considering the weight of the products (each approximately ranges from 0.3 kg to 7 kg).

Figure 8 Foundry Shop Material Handling

Manual carrying of dangerous or hazardous materials is a major source of hazards and problems for industrial workers [19]. In the case of the Foundry Shop, this may affect not only the efficiency and effectiveness of the workers due to job strain [20] but also their health because of the risk in handling hot liquid such as melted aluminum (Fig. 8). This manual handling of materials will indeed cause the workers CTD’s (Cumulative Trauma Disorders). Figure 6 Foundry Shop Material Handling Furthermore, the production area of the Foundry Shop is not properly ventilated. It has no exhaust fan as well as There is also an observed poor material handling in windows that can allow fresh air to enter the production area. transferring the aluminum scrap to the kiln using only a wheel The temperature in the molding area is too hot (37ºC - 41ºC) borrow. Another is the transfer of melted aluminum to the due to heat radiated from the kiln where aluminum scraps are molding area using a dipper that is done manually. melted. To reduce the high temperature inside the production area, electric fans were provided for the workers. Hedge [21] presented a clear association between office work performance and indoor environment conditions. Applying a temperature comfort zone (20ºC - 25ºC) to workplace will reduce energy consumption, cost, error by 44%, and saves in lost productivity.

IV. CONCLUSION AND RECOMMENDATION Adverse ergonomic working conditions can cause visual, hearing and muscular strains for example eye strain, cerebral pains, exhaustion, MSDs such as chronic back, neck and shoulder torment, Cumulative Trauma Disorders (CTDs), Repetitive Strain Injuries (RSIs), and Repetitive Motion Injuries (RMIs). Furthermore, awkward working posture Figure 7 Foundry Shop Material Handling affects the productivity of workers and it is evident through the results of the REBA and RULA assessment that the Safety measure is one of the most important aspects to be activities of the foundry workers are very risky and need considered in a production system. The workers of the immediate investigation and changes. foundry shop do not have proper uniform and safety gears Considering the weight of the products produced which such as gloves (Fig. 7), face mask and ear piece to protect are being transferred manually from one process to another, them from possible risks inside the workstation. Their skin the transfer causes Cumulative Trauma Disorders. was also exposed to health hazard such as skin lesions [18] Improvement of material handling equipment is because of scrap aluminum. Moreover, signages for safety recommended such as trolleys, rolling shelves or belt instructions or warnings are not posted which could increase conveyors. Having these materials will also lessen the transfer the occurrence of accidents inside the working area. time from one process to another leading to reduction of the current production time. To reduce the noise hazard in the foundry shop, it is recommended to have all workers be fitted with proper hearing protection to lower their exposure limits. Give more attention to the shearing operators and kiln operators. Another recommendation is to have an annual audiogram testing to verify that workers are not showing signs of hearing loss. An exhaust ventilation system is recommended around

Published By: Retrieval Number: A9702109119/2019©BEIESP Blue Eyes Intelligence Engineering DOI: 10.35940/ijeat.A9702.109119 582 & Sciences Publication International Journal of Engineering and Advanced Technology (IJEAT) ISSN: 2249 – 8958, Volume-9 Issue-1, October 2019 the furnace area of the foundry, specifically when aluminum is 19. R. Sharma, and R. Singh, “Work-related musculoskeletal disorders, job melted. This will also lessen the temperature inside the stressors and gender responses in foundry industry,” International Journal of Occupational Safety and Ergonomics, Vol. 20 (2014), No. 2, production area and will help circulate fresh air. Workers will pp 363 – 373. feel more comfortable and can perform their jobs effectively 20. G.M. Mohan, S. Elangovan, P.S.S. Prasad, P. Rama Krishna, and A.K. and efficiently. Mokkapati, A.K, “Prevalence of job strain among Indian foundry shop Illumination may increase by painting the wall of the floor workers,” WORK: Journal of Prevention, Assessment & Rehabilitation, Volume 30 (2008), Number 4, pp 353 – 358. production area with lighter color such as glossy white or light 21. A. Hedge, “Linking Environmental Conditions to Productivity,” cream. This will also improve the temperature in the Ergonomics Conference and Exposition, New York (2004). production area. In general, maintaining health and safety practices will provide a much better way for the production performance of AUTHORS PROFILE the foundry shop as well as the its workers. Furthermore, it will prevent and ultimately impede any progression of future Anna Liza C. Nacion, hazards in the workplace if proper uniforms and protective Education: Doctor of Technology (Dissertation gears will be provided. Writing), Graduate of MBA, BS . For further study, variables such as worker’s Innovation Center Manager performance must be considered to show the effects of an ergonomically designed work station in the worker’s productivity and efficiency. Publications: 1. Web-Based ECE DHVTSU Licensure Examination: Data Analysis Tool; IJEAT, ISSN: 2249-8958, Volume-8, Issue-3S, February REFERENCES 2019 2. Ethical Behaviors of Industrial Engineers in Luenthai International 1. S. Niu, “Ergonomics and Occupational Safety and Health: An ILO Group Philippines Incorporated: Basis for Development of the Perspective,” Applied Ergonomics 41 (2010), 744 – 753. Program; EAR, ISSN: 2286-4822, Volume V, Issue 9, December 2. B. Pearce, “Stemming the MSD Tide,” Safety Health Practices (2003), 2017 38 – 40. 3. Just-in-Time System: An Assessment on its Application in the 3. Dorhrman Consulting (2018, May 12). What is Ergonomics? Retrieved Manufacturing Industry in Pampanga; EAR, ISSN: 2286-4822, from https://www.ergonomics.com.au/what-is-ergonomics/ Volume V, Issue 8, November 2017 4. R. Burgess-Limerick, “Participatory Ergonomics: Evidence and 4. Performance Evaluation on Hydrokinetic Energy: A Global Implementation Lessons,” Applied Ergonomics 68 (2018) 289 – 293. Review; EAR, ISSN: 2286-4822, Volume V, Issue 8, November 5. M. Middlesworth, (2017, November 5). Five Proven Benefits of 2017 Ergonomics in the Workplace. Workplace Ergonomics 101. Retrieved

from https://ergo-plus.com/workplace-ergonomics-benefits/ Research Work: 6. I. Kuorinka, B. Jonsson, A. Kilbom, H. Vinterberg, F. Biering-Sørensen, 1. Speed Bump Flip Plate Mechanism of Electric Vehicle Charging G. Anderson, and K. Jørgensen, “Standardized Nordic Questionnaires Station for the Analysis of Musculoskeletal Symptoms,” Applied Ergonomics 2. A Portable Waste-Energy Recovery Equipment System Using 18(1987): 233 – 237. Plasma Technology 7. DOE. Guidelines on Energy Conserving Design of Buildings. 3. Design and Development of Sustainable Water Supply for Aeta Department of Energy (2007). Community in Sitio Camachile Nabuclod using Hydraulic Ram 8. Safe Work Australia. Guide to Managing Risks Associated with Pump Foundry Work (2013). 4. Design and Development of Disaster-Use Converted Ketch 9. S.C. Mali, and R.T. Vyavahare, “RULA Analysis of work-related 5. E-Trace: A Web-Based Analysis Tool for the Employability of EcE disorders of foundry industry worker using digital human modeling Graduates of DHVTSU with GSM-Based Notification Server (DHM),” International research journal of engineering and technology 6. Foldable Evacuation Homes: An efficient Response to Disasters volume 2(2015), issue, 5, pp. 1373 – 1378. 7. Policy Implementation of the RA 9003 in the Philippines: A case 10. N.A. Ansari and M.J. Sheikh. “Evaluation of Work Posture by RULA Study of Pampanga and REBA: A Case study,” IOSR Journal of Mechanical and Civil 8. Uncovering Job Demand in Region III: Basis for Curricular Engineering, Volume 11, Issue 4 Ver. III (Jul-Aug 2014), pp. 18 – 23. Development Program of DHVTSU 11. W.M. Keyserling, M. Brouwer, and B.A. Silverstein, “A for

evaluating ergonomic risk factors resulting from awkward postures of Membership: the legs, trunk and neck”, International Journal of Industrial International Association of Engineers ergonomics, (1992): 293 – 301. Philippine Association of Researchers & Statistical Software Users 12. S. Hignett, and L. McAtamney, “REBA: A Survey Method for the Pampanga Research Educators Organization Investigation of Work-Related Upper Limb Disorders,” Applied

Ergonomics (2000).

13. L. McAtamney, and E.N. Corlett, “RULA: a survey method for the

investigation of world-related upper limb disorders,” Applied Alma L. Tangcuangco, Doctor of Technology Ergonomics (1993). (Dissertation Writing), Graduate of MEP-EE, BS 14. S.C. Mali, and R.T. Vyavahare, “An Ergonomic Evaluation of an Electrical Engineering Industrial Workstation: A Review,” International Journal of Current Science Technology and Engineering Center Manager Engineeering and Technology Vol. 5(2015), No. 3, pp 1820 – 1826.

15. T. Armstrong, M. Marshall, and B. Martin, “Exposure to forceful utho r-2

exertions and vibration in a foundry,” International Journal of Photo Publications: Industrial Ergonomics, Vol. 30 (2002), No. 3, pp. 173 – 179.

16. A.M. Zakaria, K.H. Noweir, and G. El-Maghrabi, “Evaluation of 1. Development of 150 Watts, 12V Hydraulic Wheel DC Generator for a Occupational Hazards in Foundries,” The Journal of the Egyptian Farm at Brgy. Ligaya, Pulungmasle, Guagua, Pampanga, EAR, ISSN: Association, Vol. 80 (2005), No. 3 & 4, pp. 433 – 462. 2286-4822, Volume V, Issue 8, November 2017 17. S. Anandhababu, P. Vijay, A. Mohan, and P. Mohankumar, 2. Performance Evaluation on Hydrokinetic Energy: A Global Review; “Comprehensive evaluation on occupational hazards due to noise,” EAR, ISSN: 2286-4822, Volume V, Issue 8, November 2017 Indian Journal of Science, 16 (2015), No. 52, pp 73 – 76.

18. R.B. More, V.A. Sawant, and R.S.P. Dubal, “Impact of foundry Research Work: environment on skin of foundry workers,” Vol.1 (2011), Issue VI, pp 1. Speed Bump Flip Plate Mechanism 1-4. ISSN No 2031-5063. of Electric Vehicle Charging Station

Retrieval Number: A9702109119/2019©BEIESP Published By: DOI: 10.35940/ijeat.A9702.109119 Blue Eyes Intelligence Engineering 583 & Sciences Publication

Utilization of Participatory Ergonomics for Workstation Evaluation Towards Productive Manufacturing

2. A Portable Waste-Energy Recovery Equipment System Using Plasma Technology 3. Development of a Single Phase to Three Phase Rotary Type Converter with Motor Control for AC Machinery Laboratory Equipment

Membership: Institute of Integrated Electrical Engineers of the Philippines Philippine Association of Researchers & Statistical Software Users Pampanga Research Educators Organization

Published By: Retrieval Number: A9702109119/2019©BEIESP Blue Eyes Intelligence Engineering DOI: 10.35940/ijeat.A9702.109119 584 & Sciences Publication